Inspection system

ABSTRACT

An inspection system is configured for use with a conveyer apparatus including carrier bars. Each carrier bar conveys pellet-shaped articles along a predetermined path. The inspection system includes at least one camera unit for sensing a predetermined characteristic of the pellet-shaped articles, a removal unit, and a controller. The removal unit, downstream from the at least one camera unit, removes selected pellet-shaped article(s) from the carrier bar(s) depending on whether the characteristic is sensed by the at least one camera unit. The controller is in communication with the at least one camera unit and the removal unit. The controller provides a signal to the removal unit in accordance with the sensed characteristic. The removal unit includes a rotatable ejection drum having extended vacuum nozzles along its length, equal to the number of articles conveyed in each carrier bar. Each vacuum nozzle selectively removes article(s) from the carrier bar(s) by suction.

CROSS-REFERENCE TO APPLICATION

This application is a continuation of application Ser. No. 16/227,972filed Dec. 20, 2018, now pending, which is a continuation of applicationSer. No. 15/670,033 filed Aug. 7, 2017, now U.S. Pat. No. 10,201,837,which is a continuation of application Ser. No. 15/271,799 filed Sep.21, 2016, now U.S. Pat. No. 9,757,772, which is a continuation ofapplication Ser. No. 14/970,961 filed Dec. 16, 2015, now U.S. Pat. No.9,468,948, which is a continuation of application Ser. No. 14/799,740filed Jul. 15, 2015, now U.S. Pat. No. 9,259,766, which is acontinuation of application Ser. No. 14/293,307 filed Jun. 2, 2014, nowU.S. Pat. No. 9,101,962, which is a continuation of application Ser. No.13/740,684 filed Jan. 14, 2013, now U.S. Pat. No. 8,770,413, which is adivisional of application Ser. No. 13/149,140 filed May 31, 2011, nowU.S. Pat. No. 8,373,081, which claims the benefit of ProvisionalApplication Nos. 61/485,109 filed May 11, 2011, 61/457,022 filed Dec. 9,2010, and 61/344,150 filed Jun. 1, 2010, the entire contents of each ofwhich are hereby incorporated by reference in this application.

FIELD OF THE INVENTION

The present invention relates to a system for inspecting and removingpellet-shaped articles (e.g., tablets) from a conveyer apparatus basedon predetermined criteria.

BACKGROUND OF THE INVENTION

Processing of tablets, such as inspecting, marking, and/or laserdrilling of tablets, is known in the art. Inspection units are typicallyconfigured to inspect and remove tablets from a conveyer mechanism thathave been improperly processed in a previous processing operation.Previous processing operations may include marking the tablets withindicia, coloring the tablets, laser drilling holes in the tablets,and/or coating the tablets. These processing operations are typicallycompleted upstream from the inspection unit such that the inspectionunit may inspect if these processes have been properly completed.

It is important for the manufacturer to carefully inspect thepellet-shaped articles for defects, such as an improperly printed orcoated side of the article, before the pellet-shaped article isdistributed to the consumer so as to ensure the quality of the productand hence protect the safety of the consumer. Moreover, such defectivearticles must be separated from the acceptable articles based on theinspection results.

SUMMARY OF THE INVENTION

An aspect of the present invention relates to a conveyer apparatusincluding a plurality of carrier bars. Each carrier bar is structured toconvey a plurality of pellet-shaped articles along a predetermined path.The conveyer apparatus may include one or more of the following aspects.For example, the conveyer apparatus may include at least one camera unitconfigured to sense a predetermined characteristic of the plurality ofpellet-shaped articles. The conveyer apparatus may include a removalunit (e.g., downstream from the at least one camera unit) structured toremove at least a selected one of the plurality of pellet-shapedarticles from at least a selected one of the plurality of carrier barsdepending on whether the predetermined characteristic is sensed by theat least one camera unit. The conveyer apparatus may include acontroller in communication with the at least one camera unit and theremoval unit, the controller providing a signal to the removal unit inaccordance with the predetermined characteristic sensed by the at leastone camera unit. The removal unit may include a rotatable ejection drumhaving a plurality of extended vacuum nozzles along its length that isequal to the number of articles conveyed in each carrier bar. Eachvacuum nozzle may be structured to selectively remove the article fromthe carrier bar by suction. Each camera unit may be configured to sensea plurality articles simultaneously. The predetermined characteristicmay include at least one of marking error, printing misregistration,particular indicia, color, gel coating, and/or laser drilled hole. Theconveyer apparatus may include a light assembly provided to the cameraunits to illuminate the articles as they are being sensed. The lightassembly may include a dome structure and one or more LED lights. Thedome structure may include a reflective interior surface adapted toreflect light from the LED lights onto the articles being sensed. Theremoval unit may selectively remove articles from the carrier bar bysuction which are acceptable and passively allows rejected ones of thearticles to be removed from the carrier bar. The removal unit mayinclude a plurality of controllable valves associated with respectivevacuum nozzles. Each of the valves may be selectively controlled by thecontroller to control vacuum pressure to the associated nozzle. Eachvacuum nozzle may include a flexible tip portion adapted to engage thearticle. The ejection drum may be releasably mounted to allow removalfor servicing, cleaning, and/or replacement to a drum having a differentnumber and/or arrangement of vacuum nozzles. The at least one cameraunit may include first and second camera units each configured to sensea predetermined characteristic of the plurality of pellet-shapedarticles. The vacuum nozzles may be structured to remove all of thearticles from the carrier bar by suction and selectively release suctionapplied to all of the articles to release the articles into either oneof an accept bin or a reject bin depending on the predeterminedcharacteristic sensed by the camera units. The ejection drum may holdarticles for a longer distance and/or period of time depending on thepredetermined characteristic sensed by the camera units. The ejectiondrum may hold acceptable articles for a longer distance and/or period oftime than rejected articles. The camera units may sense both sides ofeach article for the predetermined characteristic, and one side of eacharticle may be sensed before picking up by the removal unit and theother side of each article may be sensed after picking up by the removalunit.

Another aspect of the present invention relates to an inspection systemthat is configured for use with a conveyer apparatus including aplurality of carrier bars. Each carrier bar is structured to convey aplurality of pellet-shaped articles along a predetermined path. Theinspection system includes at least one camera unit configured to sensea predetermined characteristic of the plurality of pellet-shapedarticles, a removal unit, and a controller. The removal unit, downstreamfrom the at least one camera unit, is structured to remove at least aselected one of the plurality of pellet-shaped articles from at least aselected one of the plurality of carrier bars depending on whether thepredetermined characteristic is sensed by the at least one camera unit.The controller is in communication with the at least one camera unit andthe removal unit. The controller provides a signal to the removal unitin accordance with the predetermined characteristic sensed by the atleast one camera unit. The removal unit includes a rotatable ejectiondrum having a plurality of extended vacuum nozzles along its length thatis equal to the number of articles conveyed in each carrier bar. Eachvacuum nozzle is structured to selectively remove the article from thecarrier bar by suction.

Another aspect of the present invention relates to an inspection systemconfigured for use with a conveyer apparatus including a plurality ofcarrier bars. Each carrier bar is structured to convey a plurality ofpellet-shaped articles along a predetermined path. The inspection systemincludes first and second camera units each configured to sense apredetermined characteristic of the plurality of pellet-shaped articles,a removal unit structured to remove the plurality of pellet-shapedarticles from the plurality of carrier bars, and a controller incommunication with the camera units and the removal unit. The controllerprovides a signal to the removal unit in accordance with thepredetermined characteristic sensed by the camera units. The removalunit includes a rotatable ejection drum having a plurality of vacuumnozzles along its length that is equal to the number of articlesconveyed in each carrier bar. The vacuum nozzles are structured toremove all of the articles from the carrier bar by suction andselectively release suction applied to all of the articles to releasethe articles into either one of an accept bin or a reject bin dependingon the predetermined characteristic sensed by the camera units.

Another aspect of the present invention relates to a method forinspecting a predetermined characteristic of a pellet shaped article.The method includes conveying at least one row of articles along apredetermined path, picking up all articles from the predetermined pathby suction, sensing all articles for the predetermined characteristic,and selectively releasing suction applied to the articles to directlydeposit the articles into either one of an accept bin or a reject bindepending on whether the predetermined characteristic is sensed.

Another aspect of the present invention relates to an inspection systemconfigured for use with a conveyer apparatus including a plurality ofcarrier bars. Each carrier bar is structured to convey a plurality ofpellet-shaped articles along a predetermined path. The inspection systemincludes a removal unit structured to remove all the articles from theplurality of carrier bars by suction. The removal unit is configured toselectively release suction applied to the articles to directly depositthe articles into either one of an accept bin or a reject bin dependingon whether either side of the article is defective.

Still another aspect of the present invention relates to process orprint error traceability. Defects or other errors may be detected. Oneor more components of the apparatus may be associated with the defect orerror, e.g., based on a positional relationship and/or time as to whereand when the defect or other error occurred. For instance, certainexample embodiments may track the area in the carrier bar from which adefect product is removed. That area may have a corresponding locationin the printing or other upstream component. The area on a design ortransfer roll in a printing application, for instance, may be furtherspecified with reference to the time at which the error occurred. Acount of errors for particular locations may be maintained and displayedto the user, e.g., in a matrix type layout corresponding to the carrierbar and/or other layout of the apparatus in certain example embodiments.Errors may be logged, and/or reports may be generated (potentiallyautomatically) if the number of errors exceeds a predeterminedthreshold. The threshold values may be determined with reference to aparticular area in the matrix, whether that area be a single pocket ofan individual roll bar, a row of pockets or a column of carrier bars, acluster, etc.

Still another aspect of the present invention relates to techniques foridentifying the origin of a detected area on a carrier medium along aprocessing path.

Still another aspect of the present invention relates to an interfacehaving a grid-like display to illuminate where errors have beendetected. In this way, potential problems may be identified.

Still another aspect of the present invention relates to the provisionof multiple smart cameras or multiple sets of smart cameras. Thedetection of errors may be distributed to the individual cameras and/orthe individual sets of cameras, e.g., if they are provided withrespective processors. In some forms, one set of cameras may beresponsible for detecting coarse or larger defects or errors, whereas asecond set of cameras may be responsible for detecting finer defects orerrors. Color and/or black and white or grayscale cameras may beprovided to serve these and/or other functions. Smart cameras may bescalable and in some cases may reduce (and sometimes even completelyeliminate) the need to transfer raw or processed image data. Forinstance, in some forms of the invention, the only data that may betransmitted from a smart camera may be an indication as to whether thereis a detected error or defect that should be tracked and/or addressed(e.g., through product removal). The number of each type of camera mayvary and need not be the same. They may be provided in a ratio relativeto one another and/or to the size of the carrier bar transporting theproduct thereunder. The cameras may be positioned in subsequent stages.Where the same numbers of cameras are provided in each stage, they maybe substantially in-line or staggered. Where different numbers ofcameras are provided, they may be staggered, centered relative to oneanother, or provided in some other relative position. Some overlap asbetween adjacent cameras in a stage may be desirable, e.g., forincreasing accuracy and/or ensuring adequate coverage. A visualdetection system of this or other sort may be provided or retrofitted toan apparatus in certain situations.

Still another aspect of the present invention relates to an ejectionsystem that selectively removes products identified as being defective,damaged, or otherwise inappropriate, and/or that may be provided orretrofitted to an apparatus in certain situations. The ejection systemmay involve vacuum removal techniques as discussed herein.

Still another aspect of the present invention relates to an improveduser interface. The user interface may facilitate changeover as betweendifferent predefined or custom defined recipes, e.g., for differentproducts. The user interface may adjust relevant software settings,e.g., for different hardware configurations. The user interface may helpkeep track of metrics regarding product acceptance, rejection, yields,etc., e.g., on a camera-by-camera basis, on a type of camera by type ofcamera basis, on a carrier-by-carrier-basis, etc. These metrics may bevisualized together with, or separate from, a matrix of where the errorshave been detected in certain implementations.

Still another aspect of the present invention relates to a trainablevisual detection system. The visual detection system may be trainedagainst a product known to be acceptable. Pattern recognition may beperformed as to the “master” product, and subsequent scans may becompared against this “master.” Tolerances also may be set as to thedegree of pattern matching required for an acceptable product or adegree of errors at which products should be removed. Such tolerancesmay vary based on a particular recipe, product, legal or other standardor guideline, etc.

Still another aspect of the present invention relates to hardwarechangeover enabled by carrier bar replacement, vacuum shoe/drumreplacement, camera addition/subtraction/repositioning, etc.

One feature of certain forms of the invention relates to the ability toaccommodate fast product handling from the inlet hopper to the carrierbars, and through the equipment. As will be appreciated, the actualproduction rate is a function of product size, shape, and lubricity.However, in certain examples, the product handling through this stretchof the apparatus may be at a rate of 250,000 to 400,000 tablets perhour, with a low (and sometimes no) amount of product being damagedthrough the process.

Another feature of certain forms of the invention relates to a colorvision or imaging system configured to differentiate between differentcolors of products, e.g., to help avoid, and stop production in theevent of, cross contamination, to weed out defective products, etc.

Another feature of certain forms of the invention relates to a highresolution vision or imaging system that inspects the product to helpensure that print quality is legible and correctly aligned on theproduct. Confirmation may be made by an integrated vision system,suitable in some examples for rejecting 99% or higher of non-passableproduct based on individual characters with an accuracy of at least 95%.The system may in some examples reject at least 99.9% of tablets withmajor defects.

Another feature of certain forms of the invention relates to anapparatus having a configuration such that product that does not passthe visual inspection test will be considered rejected and be segregatedfrom acceptable product.

Another feature of certain forms of the invention relates to the abilityto log and record data at runtime, with the logs being stored as batchor individual reports that are retrievable by a user/operator.

Another feature of certain forms of the invention relates to the abilityto produce high quality printed product at production rates with areduced amount of operator interface required during use.

Still another feature of certain forms of the invention relates to theability to detect problems that occur when the ink does not fully adhereto a product, when coatings on products flake off (e.g., contaminatingthe ink), indistinct markings are made, the incorrect products areimproperly introduced into the batch, etc.

Still another feature of certain forms of the invention relates to colorinspection techniques for products.

Still another feature of certain forms of the invention relates to animproved user interface that facilitates software and/or hardwarechangeover, makes it possible to diagnose problems by tracking whereand/or when in the apparatus problems are noticed and thus likely tohave occurred, enables compliance with relevant regulations based onfunctional certification, and/or the like.

Still another feature of certain forms of the invention relates to oneor more groups of one or more cameras. Such cameras in some forms of theinvention may be “smart” cameras having processors collocated with them,allowing for distributed processing that potentially increasesthroughput with the addition of new modules.

Still another feature of certain forms of the invention relates toprinter error traceability, through which it is possible to reduceprinting and/or other processing errors by identifying the source of theerror (e.g., a flat spot on a design roll, etc.).

Still another feature of certain forms of the invention relates to anadjustable and/or removable vacuum drum, optionally having retractablebearings.

Still another feature of certain forms of the invention relates to anejection manifold.

Still another feature of certain forms of the invention relates to thepresence of a retrofittable vision and/or ejection system.

Still another feature of certain forms of the invention relates tosimplified changer over, involving a vacuum shoe, vacuum drum bars, andproduct/carrier bar conversion. In certain forms of the invention, thesehardware components may be changed over with the aid of a user interfacethat helps account for these and/or other changes. For instance, thesoftware may help plan for more or fewer row bars, different numbers ofpockets in the different row bars, etc.

Other aspects, features, and advantages of this invention will becomeapparent from the following detailed description when taken inconjunction with the accompanying drawings, which are a part of thisdisclosure and which illustrate, by way of example, principles of thisinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings facilitate an understanding of the variousembodiments of this invention. In such drawings:

FIG. 1 is a perspective view of a conveyer apparatus including aninspection system according to an embodiment of the invention;

FIG. 2 is a side view of the conveyer apparatus of FIG. 1, with aportion of the apparatus shown in cross-section;

FIG. 3 is a top view of the conveyer apparatus of FIG. 1;

FIG. 4 is a front view of the conveyer apparatus of FIG. 1;

FIG. 5 is a schematic view of an inspection system according to anembodiment of the invention;

FIG. 6 is a perspective view of the inspection system of FIG. 5;

FIG. 7 is an exploded view of the inspection system of FIG. 5;

FIG. 8 is an exploded view of the ejection drum, vacuum shoe, and vacuummanifold including solenoid pack of the inspection system of FIG. 5;

FIG. 9 is a perspective view of the ejection drum, vacuum shoe, andvacuum manifold of FIG. 8;

FIG. 10 is a perspective view of the vacuum shoe of FIG. 8;

FIG. 11 is a side view of the vacuum shoe of FIG. 8;

FIG. 12 is a cross-sectional view through line 12-12 of FIG. 11;

FIG. 13 is an end view of the vacuum shoe of FIG. 11;

FIG. 14 is a perspective view of the vacuum shoe of FIG. 8;

FIG. 15 is a side view of the vacuum manifold of FIG. 8;

FIG. 16 is a perspective view of the vacuum manifold of FIG. 8;

FIGS. 17 and 18 are perspective views of a dome structure for a lightassembly according to an embodiment of the invention;

FIG. 19 is a cross-sectional view of a nozzle for an ejection drumaccording to an embodiment of the invention;

FIGS. 20-1 to 20-4 are schematic views showing the releasable mountingof the ejection drum according to embodiments of the invention;

FIG. 21 is a schematic view of an inspection system according to anotherembodiment of the invention;

FIG. 22 is a flowchart providing an example of how of certain exampleembodiments may operate;

FIG. 23 is an example control system architecture according to anexample embodiment;

FIG. 24 is a side view of the conveyer apparatus of FIG. 1, with aportion of the apparatus shown in cross-section, modified to includeadditional cameras in accordance with an example embodiment;

FIG. 25 is a top view of the conveyer apparatus of FIG. 24;

FIG. 26 is an example operation screen that may be displayed to auser/operator in accordance with an example embodiment;

FIG. 27 is an example operation screen that includes overall equipmenteffectiveness (OEE) performance monitoring in accordance with an exampleembodiment;

FIG. 28 is an example design roll data matrix screen in accordance withan example embodiment;

FIG. 29 is a screen that provides a single point of control for printingand vision system access in accordance with an example embodiment;

FIG. 30 is an example screen for vision system setup and logo trainingin accordance with an example embodiment;

FIGS. 31 and 32 are example user maintenance screens in accordance withan example embodiment; and

FIG. 33 is an example automatic vision system calibration verificationscreen in accordance with an example embodiment.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

The following description is provided in relation to several embodimentswhich may share common characteristics and features. It is to beunderstood that one or more features of any one embodiment may becombinable with one or more features of the other embodiments. Inaddition, any single feature or combination of features in any of theembodiments may constitute additional embodiments.

Certain forms of the invention relate to a variable ramp printer,including an offset printer with automatic print quality visioninspection and/or defective product removal. Thus, certain forms of theinvention are configured to produce high-quality printed product atproduction rates with a reduced amount of operator interface andmaintenance. Safety devices may be built into the system, e.g., to helpensure safe operation and maintenance by trained personnel.

As an overview of certain example techniques, it is noted that thevariable ramp printer may operate by placing product into an inlethopper located at a ramp section of the system. Carrier bar pockets arecustom designed to work with a specific ramp feed angle determinedthrough testing. The product therefore may be gravity-fed from the inlethopper to the carrier bar pockets, where it is properly oriented andconveyed past rotating brushes, designed to provide an increased carrierbar fill rate, while also reducing the likelihood of stray product fromexiting the hopper. The product is transported through the print unit,where the engraved design roller transfers ink to the offset roller,which then transfers the logo on to the product. The product is conveyedalong an ink drying section, where color cameras verify the tabletcolor. Non-conforming product is gravity discharged off the front of theconveyor, assisted by a discharge blow-tube. Following the colorinspection, a row of grayscale cameras captures high-resolution imagesof the product surface and the printed logo. The image is analyzed bythe vision system to determine if the printed logo meets the qualitystandard defined by a pre-trained reference logo image (e.g., apre-trained golden reference logo image). If the printed logo qualitypasses this first test, the position of the logo on the tablet isinspected to verify that it is centered within a pre-set tolerance.Other visible features and/or blemishes in the captured image may alsobe inspected so as to help identify and/or capture, for example, brokenproducts, coating defects, etc. The results of the inspections areentered into the product tracking system, which stores an accept, rejector empty-pocket result for each carrier bar pocket location along theconveyor. A time or other index may be associated with each row bar.Non-conforming product is gravity discharged off the front of theconveyor, assisted by a discharge blow-tube. Product that is determinedto be acceptable by the automatic vision inspection system is lifted outof the carrier bar pockets using soft, silicone vacuum suction cupsrotating around a synchronized product eject transfer drum. The acceptedproduct is transferred from the eject drum to the discharge chute whereit exits the machine. As will be appreciated, the example process stepsmay be performed in any suitable order.

It is noted that the printing, conveyor, inspection, ejection, and/orother systems may be provided in any suitable combination orsub-combination. Furthermore, various “sub-aspects” of the visualinspection system also may be provided in various combinations andsub-combinations. For instance, the color and grayscale imagingtechniques may be provided together or separately. Furthermore, certainfunctions described above as involving color cameras may be performedwith grayscale cameras, and vice versa. The imaging techniques may alsobe provided as a part of a retrofit package that may be added toexisting conveyor or other type systems.

Although certain example embodiments have been described as including aramp type printer, a flat or more flat type system also may be used inconnection with different embodiments of this invention. In other words,ramping and/or gravity fed techniques are not necessarily required byall embodiments.

FIGS. 1-4 illustrate a conveyer apparatus 10 including a plurality ofcarrier bars 12 structured to transport or convey a plurality ofpellet-shaped articles along a predetermined conveyer path. It should beappreciated that the carrier bars may be adapted for use with anysuitable pellet-shaped article, e.g., tablets, capsules, pills, etc.

The apparatus may be a ramp-type conveyer including incline, horizontal,and decline portions as disclosed in U.S. Pat. No. 5,655,453, which isincorporated by reference in its entirety. The conveyer path representsthe direction of travel of the carrier bars.

The conveyer apparatus 10 is supported upon a frame 14 having spacedlegs for providing a free-standing support. The frame is also structuredto support a feed hopper 16, a marking apparatus 18, an inspectionsystem 50, and a display monitor 20 that displays diagnostic informationto an operator.

In certain examples, the frame may include various sections orcomponents for supporting the system in whole or in part. A flat bedsection may provide support for the overall system and allow mountingfor print and inspection systems. A ramp section may include anadjustable, angled ramp feed system that is designed to increase thecarrier bar pocket fill rate. The product infeed hopper may be locatedon the ramp section of the frame. A DC linear actuator motor may beprovided to help move the ramp section up and down. The infeed hopperassembly may be used to transfer the product into the carrier barpockets. The hopper level may be properly maintained to reduce thelikelihood of damage to the product and achieve the desired increasedcarrier bar pocket fill rate. Leveling Casters may be mounted on thebottom of the base frame assembly to allow portability and to providethe ability to level the system. An operator control panel may bemounted to the base frame assembly to allow an operator to interfacewith the variable angle ramp print system. A handwheel may be used tomove the product carrier bars in the forward direction, e.g., when thereis no power to the motors.

In the illustrated embodiment, each of the carrier bars includes one ormore article receiving pockets disposed transversely along their length.The pockets of the carrier bars operate to receive and entrain articlesfrom the feed hopper 16, and move the articles along the conveyer path.The feed hopper may be provided along an incline portion of theconveyer. In other words, tablets may be conveyed through the systemusing carrier bars with machined pockets, custom designed for theproduct to be imprinted. The carrier bars may be spaced apart along theconveyor, e.g., at regular intervals (for example, 1″ intervals). Thecarrier bars may be designed for ease of changeover, e.g., incorporating“snap-off” removal and/or “press-on” insertion features. In an exampleproduct feed system, a variable speed carrier bar conveyor system mayutilize precise servo motor position control. The conveyor servo motormay be arranged along the main axis of the machine, and the print unitservo motor may be electronically geared to this axis.

A primary hopper brush may help ensure that only properly orientedtablets are conveyed through the system. The brush rotational speed maybe controlled from via a user interface. The primary hopper brush may bean upper one of two large brushes. A secondary hopper brush, bycontrast, may be used to agitate the product and assist product feedinginto the carrier bar pockets. The brush rotational speed for thesecondary hopper brush also may be controlled via the user interface,and the secondary hopper brush may be the lower of the two hopperbrushes. A laydown brush may help ensure that the product is properlyseated in the carrier bar pockets and also may help reduce thelikelihood that tablets that are outside of the carrier bar pocketsenter the imprinting area. A bar vibrator, located under the carrierbars in the flat-bed area just before the lay down brush, may helpensure that the product is properly seated in the carrier bar pockets.The hopper blowback tube contains of a set of air nozzles designed toremove product from the carrier bar pockets before they exit the hopper.When the stop button is pressed, the hopper blowback nozzles areactivated to restrain the product within the hopper while the conveyorsystem continues to run for a set distance until the carrier bars havebeen cleared of product.

The carrier bars are conveyed past the marking apparatus 18 for markingdesired indicia onto the articles. In the illustrated embodiment, themarking apparatus 18 includes a design roll that forms the indicia to beapplied to the articles, and which is disposed within an appropriatesupply of ink (not shown), and a printing roll which is in contact withboth the design roll and the articles which are to receive the indicia,for transferring the ink-laden indicia from the design roll to thearticles in question. However, it is contemplated that the markingapparatus may be an ink jet.

If an offset printer is used, it may have the following examplestructure. A metal design roller, engraved with the logo designs, mayrotate within an ink pan. Ink in the pan fills the engravings. Thedesign roller may in some cases be referred to as a rotogravurecylinder. A doctor blade may wipe the excess ink from the design rollerback into the ink pan. A rubber offset roller may contact the designroller, pick up the ink from the design roller etches, and transfer theink to the product surface. As alluded to above, an ink pan may hold theink for the design roller. As the design roller rotates, the mixingaction may help maintain the consistency of the ink within the pan. Anoffset roller stripper plate may help reduce the likelihood of productsticking to the offset roller after printing. The stripper plate may becustom designed for the product to be printed. A print unit servo motormay be electronically geared to the conveyor for precise synchronizationof the print unit relative to the carrier bars.

Following the marking apparatus, the carrier bars convey the articlespast the inspection system 50 according to an embodiment of theinvention. The inspection system is structured to inspect and removespecified pellet-shaped articles from the conveyor apparatus based onpredetermined criteria.

In illustrated embodiment, the inspection system 50 includes a cameraunit 60, a removal unit 70, and a controller 80. In use, each article Ais inspected by the camera unit 60 for one or more particular criteriaor characteristics (e.g., marking error, printing misregistration,etc.), and then brought past the removal unit 70 configured to removeacceptable articles that have met the particular characteristics asdetermined by the camera unit and eject the acceptable articles into anaccepted product discharge chute or accept bin 90. Defective or flawedtablets that have not met the particular characteristics are allowed topass by the removal unit and are discharged into a separate rejectedproduct discharge chute or reject bin 92.

The camera unit 60 is provided along the conveyer path and is configuredto sense a predetermined characteristic of the article. In theillustrated embodiment, the camera unit is configured to sense whetherone side of the article has been properly marked. If the camera unitdetermines that a tablet-shaped article has been properly marked, thenthat particular article will be removed by the removal unit from theconveyer apparatus.

One or more camera units may be provided to conveyer apparatus, witheach camera unit configured to sense a plurality of pocketssimultaneously. Each camera unit may be configured to monitor any numberof pockets provided in each of the carrier bars. For example, eachcamera unit may be dedicated to a certain area of the carrier bar andconfigured to monitor the pockets provided in such area of the carrierbar regardless of number of pockets. The fields of view of the cameraunits may overlap with one another to ensure that the entire carrier baris monitored. The controller may be adjusted to set the number ofpockets being monitored by each camera unit. In an exemplary embodiment,each camera unit may be configured to monitor an area including 2-8pockets, e.g., 4 camera units provided to monitor carrier bar with 24pockets with each camera unit configured to monitor 6 pockets.

Also, it should be appreciated that the camera unit may be configured tosense other predetermined characteristic of the article (e.g.,particular indicia, color, gel coating, laser drilled holes, etc.). Thatis, other processing operations may precede the inspection system, andthe inspection system may be configured to inspect the accuracy of suchoperations and remove articles accordingly.

A diffuse reflectance LED light assembly 62 is provided to the cameraunit 60 to properly illuminate the respective side of the article as itis being sensed. For example, the light assembly 62 includes a domestructure 63 and one or more LED lights 64 provided along the lower edgeof the dome structure. The light assembly provides an indirect lightingarrangement in which light from the LED lights is not directly focusedonto the carrier bars, i.e., LED lights oriented away from the carrierbars and the dome structure reflects light onto the carrier bars and/ordefines an illuminated area or lighted interior space. In an exemplaryembodiment, the interior surface 63(1) of the dome structure 63 mayinclude a reflective surface (e.g., white coating, e.g., paint orlacquer) adapted to reflect light from the LED lights 64 onto thecarrier bars and the articles to be sensed. In an embodiment, each LEDlight is configured to intermittently emit light (e.g., strobe typelighting), with the light appropriately timed with inspection by thecamera unit. One or more openings 66 are provided to the top of the domestructure 63 and aligned with a respective camera unit 60 to allow thecamera unit to operate therethrough. Each camera unit may be adjustablymounted (e.g., slidably mounted for lateral or side-to-side movement)with respect to the conveyer apparatus for optimal performance.

FIGS. 17 and 18 show a dome structure 63 according to an embodiment ofthe invention. As illustrated, the dome structure is in the form of asingle elongated dome with one elongated opening 66 that allows the oneor more camera units to operate therethrough. In an alternativeembodiment, the light assembly may provide individual domes forindividual cameras.

However, alternative and/or additional arrangements may be provided toenhance lighting of the carrier bars and/or sensing of the articles bythe camera unit. For example, the carrier bars may include a coating(e.g., white coating) to enhance the contrast between the article andthe carrier bar, for improved inspection efficiency/results. In anotherexample, the carrier bars may be constructed of a material (e.g.,plastic material) so they are clear or transparent, which may allowsensing the bottom side of each article without removing the articlefrom the carrier bar, i.e., camera unit able to sense through thethickness of the carrier bar. Since the top side will remain exposed,the entire article can be inspected with the article remaining in thesame orientation.

The camera units provide signals to the controller 80, which signals theremoval unit so that specified articles can be removed from the conveyerapparatus.

Another example vision inspection system may include the same or similarcomponents functioning in the same of similar ways. For instance, one ormore high resolution black and white or grayscale inspection cameras maybe provided. In one form, four inspection cameras mounted adjacent toeach other, spaced apart at regular intervals (e.g., 3.38″ apart) andabove the carrier bars. The number of and distance between adjacentcameras, as well as the height above the carrier bars, may be selectedbased in part on the length of the carrier bars, focal distance of thecameras, etc. For example, if the maximum printable area of a carrierbar is 13.75 inches and four cameras are provided, each camera may beresponsible for inspecting a 3.75 inch area of the carrier bar. Thefield-of-view (FOV) of each camera may be made to overlap the FOV of theadjacent camera, providing the vision system with a full-view of thecarrier bar. Each camera may be a “smart camera,” e.g., in the sensethat it may have a processor integrated therein. For instance, eachcamera may have a built-in 1 GHz processor, 64 MB Flash memory and 128MB image processing memory. When a trigger is sent to the camera, itwill acquire an image, inspect the product in the carrier bar pocketsand send the results to a programmable logic controller (PLC). A colorinspection system component may include one or more (e.g., two) colorcameras mounted above the carrier bars, e.g., as described above andpossibly in connection with the variables identified above. The colorinspection system may be used to help avoid product cross contamination.Suitable color cameras include, for example, Cognex Insight 5400cameras, although other camera types may be used in differentembodiments. C-mount Megapixel lenses may be provided for the cameras insome implementations, although higher or lower resolution lenses alsomay be used in different embodiments.

Lighting connected to a strobe controller may be collocated with thecolor inspection system components or otherwise may be provided over thecarrier bars. LED lighting may be advantageous in that it may providehigh-intensity lighting. In certain embodiments, the LED lighting may beelongated high-intensity strobe white LED line lights for illumination.The LED lighting may be longer than the carrier bars. For instance, ifthe maximum printable area of a carrier bar is 13.75 inches, the LEDline lights may be 18″ long. In certain examples, more lighting may beprovided for the black and white or grayscale cameras as compared to thecolor cameras. For instance, two LED line lights may be provided for theblack and white or grayscale cameras, whereas one LED line light may beprovided for the color cameras. A lighting controller may provide asignal to the LED lights for high-intensity strobe illumination. Asindicated above, an inspection dome cover may provide for a bright,uniform “cloudy day” lighting effect for high contrast product qualityinspection. Aspects of the strobe (e.g., timing between pulses, lengthof pulses, intensity, trigger source, etc.) may be programmed and/orcontrolled.

In the illustrated embodiment, as shown in FIG. 5, the removal unit 70includes a stationary vacuum shoe 72 and a product ejection drum 75rotatable with respect to the vacuum shoe. The vacuum shoe 72 includes aconstant vacuum portion 73 communicated with a vacuum source 85, and avariable vacuum portion 74 communicated with the vacuum source via acontrollable solenoid valve 87. The product ejection drum 75 includes aplurality of vacuum nozzles or suction cups 77 communicated with thevacuum shoe.

The product ejection drum is adjustably mounted to the frame of theconveyer apparatus to allow selective adjustment of the drum withrespect to the carrier bars, i.e., drum is adjustable to adjust thedistance between the nozzles and the carrier bars or articles. Inaddition, the vacuum shoe and the ejection drum are releasably mountedto the frame of the conveyer apparatus to allow easy removal of the shoeand drum from the conveyer apparatus, e.g., for servicing, cleaning,and/or changing shoe/drum to correspond with carrier bar pocketarrangement.

FIGS. 7 and 20-1 to 20-4 show the releasable mounting of the ejectiondrum 75 according to embodiments of the invention. As illustrated, adrum mount 94 is provided to the frame 14 to releasably secure the drumin an operative position. In the illustrated embodiment, the drum mount94 includes a clamp-type arrangement with spaced apart clamp structures95 structured to support respective ends of the drum. Each clampstructure 95 includes an upper arm 95(1) and a lower arm 95(2) pivotallymounted to the upper arm 95(1). In use, the ejection drum 75 is insertedinto the spaced apart lower arms 95(2) (e.g., see FIGS. 7 and 20-1), andthen the lower arms 95(2) are pivoted into engagement with respectiveupper arms 95(1) via the hand bar 95(3) (e.g., see FIG. 20-2) to securethe ejection drum within the drum mount (e.g., see FIG. 20-3). The upperand lower arms 95(1), 95(2) of each clamp structure are secured to oneanother by a locking pin 96(1) (e.g., see FIG. 7) which may be rotatedbetween unlocked and locked positions (e.g., see FIG. 20-3). Once theejection drum is secured within the drum mount, the drum mount 94 ispivoted via the hand bar 95(3) into an operative position with respectto the carrier bars as shown in FIG. 20-4. The drum mount 94 is securedin the operative position by locking pins 96(2) (e.g., see FIG. 7) whichmay be rotated between unlocked and locked positions (e.g., see FIG.20-4). Movement of the drum mount 94 into the operative position alsomoves the gear teeth 76 on one end of the ejection drum into engagementwith the gear assembly 79 structured to rotate the ejection drum in use(e.g., see FIG. 6). One or more adjustment knobs (e.g., see adjustmentknob 97 in FIGS. 1 and 4) may be provided to adjust the position of thedrum mount and hence the ejection drum with respect to the carrier bars,e.g., selectively adjust the distance between the nozzles of theejection drum and the carrier bars. Once the drum mount and ejectiondrum are in the operative position, the vacuum shoe 72 may be insertedinto the interior of the ejection drum 75 and releasably locked inposition, e.g., via the lock handle 72(1) provided on one end of thevacuum shoe as shown in FIGS. 7 and 10 for example.

The drum 75 includes multiple sets of nozzles 77 arranged along a lengthor axis of the drum, and each set of nozzles matches the number andarrangement of pockets in each carrier bar. In an exemplary embodiment,each carrier bar includes 24 pockets separated into two staggered rowsof 12 pockets. Accordingly, the drum provides multiple sets of nozzlesseparated into groups of 24, with each nozzle associated with arespective pocket. However, it should be appreciated that other suitablenumbers of pockets may be provided to each carrier bar, and hence othersuitable numbers of nozzles.

As a result, one or more specified articles from each carrier bar may beremoved from their respective pocket as it passes by the removal unit byselectively controlling a set of nozzles. That is, each nozzle from theset is associated with a single pocket in each carrier bar, and eachnozzle may be selectively activated to permit or prevent vacuum air fromthe vacuum shoe to be applied therethrough, therefore selected articlesfrom the carrier bar may be selectively removed or picked up by thenozzles depending on whether the articles are determined to be“acceptable” or “defective” by the camera unit as described below.

If an article is determined to be “acceptable”, the controller 80signals the solenoid valve 87 to permit vacuum air to be applied to theselected variable vacuum portion 74 associated with the selected nozzle77, which allows the selected nozzle to remove (e.g., by suction) theindividual article from that pocket in the carrier bar. As the drum 75continues to rotate relative to the vacuum shoe 72, the nozzle will movefrom communication with the associated variable vacuum portion 74 to theconstant vacuum portion 73 which will continue to retain the articlewith the nozzle. Further rotation of the drum will move the nozzle outof communication with the constant vacuum portion and allow the articleto eject or fall into the accepted product discharge chute 90.

If an article is determined to be “defective”, the controller 80 signalsthe solenoid valve 87 to prevent vacuum air to be applied to theselected variable vacuum portion 74 of the selected nozzle 77. As aresult, the defective article is allowed to pass by the respectivenozzle of the drum and is discharged or falls into the rejected productdischarge chute 92.

FIGS. 6-16 show various views of the vacuum shoe 72, the ejection drum75, the vacuum source 85, and the vacuum manifold 88 including solenoidpack 89 associated with the solenoid valve. The solenoid pack 89includes one or more solenoids to match the number of valves associatedwith the axially spaced nozzles in the drum and hence the number ofpockets in each carrier bar. Each solenoid may be selectively controlledto control the valve and hence vacuum pressure to the associated nozzle.Also, each solenoid is associated with a solenoid tube 91 (e.g., seeFIG. 16), each tube 91 being communicated with the respective tube orvariable vacuum portion 74 in the vacuum shoe 72 (e.g., see FIG. 14).The drum rotates relative to the shoe as the carrier bars are conveyedalong the conveyer path. As the carrier bars pass below the drum, a setof nozzles along the length of the drum align with respective pockets ofeach carrier bar. If the articles within the pockets are determined tobe acceptable, then the solenoid associated with the nozzle aligned withsuch article is activated, e.g., to remove the article by suction fromthe pocket and release into the discharge chute for acceptable articles.For any articles that are not acceptable, the solenoid is not activatedand the article continues with the carrier bar until gravity allows thearticle to be released into the discharge chute for defective articles.In this embodiment, all articles (including acceptable tablets) areejected in the event of solenoid failure.

As best shown in FIG. 19, each nozzle 77 includes a base portion 77(1)extending from the drum 75 and a tip portion or article engaging portion77(2) provided to the free end of the base portion. The base portion77(1) defines a passage 77(3) for communicating vacuum pressuretherethrough. In the illustrated embodiment, the tip portion 77(2)includes a gusseted or bellows configuration with one or more bendableportions 77(4) to add flexibility to the tip portion. The gussetedconfiguration is structured to cushion impact with the article in use,maximize compliance by allowing article differentiation andmisalignment, and/or maximize vacuum pressure in use. In an embodiment,the tip portion (e.g., constructed of a more flexible material than thebase portion, e.g., such as silicon) may be formed separately from thebase portion and attached thereto. However, the nozzle may include othersuitable structures and may be constructed of other suitable materialsto enhance engagement with the article.

The ejection system change parts for a particular product may include avacuum shoe and an eject drum. As explained in detail above, The vacuumshoe helps channel the vacuum from the machine-mounted vacuum valves tothe corresponding row of carrier bar pockets, and the eject drumconsists of a hollow cylinder with rows of suction cups mounted to stemsaround the circumference of the drum. Each row of suction cupscorresponds to a row of carrier bar pockets. System changeover andcleaning can be accomplished very quickly with the quick-release drumand shoe mechanisms. The drum is removed by loosening the four clampingknobs on the drum support assembly and lifting the drum out of thesupport arm. A gear is located on the end of the drum which engages witha drive gear mounted inside the machine side frame. When the drum isclamped into place, it engages with the drive gear to synchronize withthe carrier bar conveyor drive. A vacuum shoe is inserted through theinner bore of the eject drum. When the vacuum shoe handle is pushedinward, it will rotate a quarter-turn and lock in place. This lockingmechanism includes a compression spring that is used to seal the shoeagainst the vacuum manifold, and a set of cam operated spring plungersand rollers to provide a seal against the inner drum surface.

It thus will be appreciated that the ejection system may work inconjunction with the vision inspection system. For example, in the eventthat the vision inspection system determines that the product isunacceptable according to predefined standards, a signal may be sent tothe controller that, in turn, will relay another signal to activate theejection system. A vacuum pump may be provided as a vacuum source. Theamount of vacuum may depend on product characteristics. However, avacuum source capable of producing up to 60 in-H₂O vacuum at 150 CFMfree air flow (5 hp blower type recommended) may provide for properoperation of the automatic vision inspection defect removal system.Higher or lower power vacuum source(s) may be provided in differentembodiments, of course. A female 2″ barbed hose fitting may be provided,and a 230 VAC, Three Phase power outlet may be located at the rear ofthe machine to provide power to an external vacuum pump. A vacuum pumpcontrol button may be provided on the control panel to switch on or offthe power to the auxiliary outlet. The number of vacuum solenoid valvesmay be selected based on the number of pockets in each row of thecarrier bar. For instance, 24 vacuum solenoid valves may be used incertain examples. If a carrier bar for a particular set of change partshas less than 24 pockets, the remaining valves may be unused for thatset of change parts. The system may be designed for fail-safe operationby “switching on” a valve to actively eject a product when the visionsystem identifies it as an acceptable product. When the inspectionsystem classifies a product as a reject, the valve will be switched offand the product will remain in the carrier bar pocket until it isrejected off of the front of the conveyor using a blow tube. If there isa failure of a solenoid valve, or if the inspection system fails to sendan accept signal, the product will go to the reject hold bin.

The ejection drum may be designed to match the pocket layout for aparticular carrier bar. The drum may have soft, silicon vacuum suctioncups to remove accepted product from each carrier bar pocket. The vacuumshoe may be mounted inside the ejection drum to channel vacuum to therow of suction cups above the carrier bar pockets with tablets as thebars move under the ejection drum. The reject blow-off tube may blow airon the carrier bar pockets to help ensure that a rejected tablet isejected into the reject bin. The reject hold bin, in turn, collects allof the failed tablets, whereas the discharge chute feeds the acceptedtablets into the storage drum.

FIG. 21 illustrates a conveyer apparatus including an inspection system250 according to another embodiment of the invention. In the previousembodiment, the inspection system determines whether one side of eacharticle has been properly processed (e.g., marked), and then the removalunit passes the articles into “acceptable” or “defective” chutes. In theembodiment of FIG. 21, the inspection system determines whether bothsides of each article have been properly processed, and then the removalunit passes the articles into “acceptable” or “defective” chutes.

The inspection system 250 includes a first camera unit 260, a secondcamera unit 265, a removal unit 270, and a controller 280. In use, oneside of each article is inspected by the first camera unit 260 for oneor more particular criteria or characteristics (e.g., marking error,printing misregistration, etc.), and then brought past the removal unit270 configured to remove each article from the conveyer apparatusregardless of the results determined by the first camera unit. Theremoval unit carries the articles past the second camera unit 265 whichinspects the other side of the articles for one or more particularcriteria or characteristics. If both the first and second camera unitsdetermine that the article has met the particular characteristics, thenthat particular article is retained by the removal unit until it isdischarged into the accepted product discharge chute 290. If one or bothof the first and second camera units determine that the article has notmet the particular characteristics, then that particular article isreleased by the removal unit and discharged into the rejected productdischarge chute 292. Thus, the removal unit 270 removes all articlesfrom the conveyer apparatus and selectively discharges the articles inresponse to signals from the first and second camera units 260, 265 intoeither the accepted product discharge chute 290 for acceptable articlesthat have met the particular characteristics or the rejected productdischarge chute 292 for defective or flawed tablets that have not metthe particular characteristics.

The first camera unit 260 (e.g., similar to the camera unit 60 describedabove) is positioned on an upper side of the conveyer apparatus to senseone side of the article, and the second camera unit 265 is positioned atthe end of the conveyer apparatus to sense the other side of thearticle. As a result, both sides of the articles are sensed by the firstand second camera units.

The first and second camera units provide signals to the controller 280,which signals the removal unit 270 so that specified articles can bedischarged from the removal unit into the proper discharge chute.

In the embodiment of FIG. 21, the removal unit 270 includes a stationaryvacuum shoe 272 and a product ejection drum 275 (with vacuum nozzles277) rotatably mounted to the vacuum shoe. The vacuum shoe 272 includesa constant vacuum portion 273 communicated with a vacuum source 285, anda variable vacuum portion 274 communicated with the vacuum source via acontrollable solenoid valve 287. The constant vacuum portion 273includes a first portion 273(1) on one side of the variable vacuumportion 274 and a second portion 273(2) on the other side of thevariable vacuum portion 274.

As the carrier bars pass below the drum 275, the nozzles 277 arecommunicated with the first portion 273(1) of the constant vacuumportion which allows the nozzles to remove (e.g., by suction) all thearticles from respective pockets in the carrier bar. As the drumcontinues to rotate relative to the vacuum shoe, the nozzles willposition the articles to be sensed by the second camera unit 265.Continued rotation of the drum moves the nozzles into communication withthe variable vacuum portion 274. If an article is determined to be“acceptable” by both the first and second camera units 260, 265, thecontroller 280 signals the solenoid valve 287 to permit vacuum air to beapplied to the selected variable vacuum portion 274 of the selectednozzle, which allows the selected nozzle to retain the individualarticle as it moves from communication with the variable vacuum portion274 to the second portion 273(2) of the constant vacuum portion. Furtherrotation of the drum will move the nozzle out of communication with thesecond portion 273(2) of the constant vacuum portion and allow thearticle to eject or fall into the accepted product discharge chute 290.If an article is determined to be “defective”, the controller signalsthe solenoid valve 287 to prevent vacuum air to be applied to theselected variable vacuum portion 274 of the selected nozzle. As aresult, the defective article is released by the nozzle of the drum andis discharged or falls into the rejected product discharge chute 292.

FIG. 22 is a flowchart providing an example of how of certain exampleembodiments may operate. In FIG. 22, tablets are loaded into the hopperin step S2202. At least some of the tablets are picked up by carrierbars in step S2204. A determination is made in step S2206 as to whetherthe tablets in the carrier bars are properly oriented. If they are not,some or all of the tablets in the carrier bar may be removed from thecarrier bar and reloaded into the hopper, and processing may be returnedto step S2202. One or more brushes may be provided for properlyorienting the products in certain instances. If they are, however, thenprint may be applied to the product in step S2208. Any suitabletechnique may be used such as, for example, offset printing, inkjetprinting, laser printing, gravure printing, etc. A determination is thenmade in step S2210 as to whether there are any color defects. If defectsare detected, then the products with the defects are rejected or markedfor rejection in step S2212 and/or the entire system may be shut down toinvestigate the cause of the problem. If there are no defects, however,the print quality is inspected in step S2214. Similar to the abovedefect test, if the product fails the product quality test, it may bedischarged, e.g., to a reject bin in step S2216. If, however, theproduct passes, then it may be discharged to a package drum in stepS2218.

In one or more steps not shown, a histogram tool may be used to checkfor the presence of products against the background of the carrier bar(e.g., light-colored tablets against a dark carrier bar). In some cases,to save processing time, the print quality check may be performed if andonly if the histogram tool indicates that a product is present.Similarly, in certain example embodiments, where two or more stages ofcameras are used, subsequent downstream processing may be performed ifand only if prior tests are passed.

The print quality tests may be performed based on pattern matchingand/or other suitable image or character recognition techniques indifferent embodiments. The image on the product may be detectedregardless of its location and orientation in the carrier bar, therebyreducing the need for precision positioning of the tablet and/or camera.Individual features may be identified and isolated within an objectimage. For instance, characteristics such as shape, dimensions, angles,arcs, and/or shading may be identified. The spatial relationshipsbetween these identified features may be correlated with features from atrained image. The correlation may account for changes in distanceand/or relative angle. By analyzing geometric information from both thefeatures and spatial relationships, the object's position can bedetermined, potentially without regard to the object's angle, size, orappearance, in certain example instances.

After being initially trained with an image of a good quality printedtable, the good image may be compared to the most recently acquiredimage. The quality of the recently acquired image may be rated based onthe match. The location of the center of the printing on the productthat was inspected may also determined to help ensure the logo iscentered on the tablet, for example. Thus, the pattern recognition andtrained image matching techniques of certain embodiments may be capableof detecting defects such as, for example, printed logo registration,incomplete printed logos, faded or blurry printed logos, double printedlogos, etc. Cosmetic defect detection may also include, for example,chipped, capped, or broken products; coating defects, stains or specs;foreign object/rogue product detection, etc.

Damage inspection may involve checking to see if the product is broken,for example. A broken tablet typically shows up as several light-coloredsections against a dark background. It therefore may be identified byusing the vision system's “blob” tool, which looks for light-coloredblobs smaller than the tablet. Coating defects also may be searched forand can sometimes be identified as a smaller white spot, because thecore of the tablet is white. The blob tool also may be used to searchfor white spots.

In some embodiments, the camera acquires the image and performs each ofthese inspections and builds a binary word that contains the inspectionresults for each of the six tablets in its field-of-view. The visionsystem may send the results to the programmable logic controller (PLC)that runs the machine. The vision system also may in addition or in thealternative send each inspection image to the corporate network where itcan be called up by the machine operators or engineers. A matrix ofresults may be maintained including, for example, a count of the numberof defects at each position.

The PLC may operate a vacuum system that picks up the tablets from thecarrier bar and moves them to a discharge chute, e.g., as describedabove. Based on the signal from the PLC, specific positions on thevacuum shoe are operated individually to either pick up or leave behindindividual tablets. The tablets that have passed the inspection arepicked up and placed in the discharge chute, while those that havefailed remain in the carrier bar. In the next step, the tabletsremaining in the carrier bar are dumped into a reject bin. This approachmakes it possible to help reduce in a positive manner the number ofindividual tablets that fail inspection and ensure that only goodtablets are passed along for packaging.

An example control system architecture will now be described inconnection with FIG. 23. A control panel 2302 provides an interfacebetween the end-user/operator and the system. From the control panel2302, the end-user may configure and operate the system according tovarious system parameters pre-programmed in connection with theunderlying computer 2304. The computer 2304 includes several components.For example, a programmable logic controller (PLC) receives signals frominputs/outputs, as well signals from the control panel 2302. In certainexamples, the PLC is the master control component of the system andcontains the main system control software. The PLC, together with theprocessor and input/output (I/O) ports and Ethernet/IP connection, helpcoordinate components in the system. For instance, the PLC communicateswith the control panel 2302 to provide an interface for the operator tomonitor and/or configure the system settings for both the print andvision parameters. One or more servo drives (e.g., first and secondservo drives 2308 a and 2308 b) in FIG. 23 communicate with the PLC toreceive motion commands and provide position and velocity feedback tothe PLC. The strobe controller 2314 may be setup through the controlpanel 2302 and may receive trigger signals from the cameras in either orboth of the color vision inspection system 2310 and the black and whitevision inspection system 2312. The cameras in the color visioninspection system 2310 and the black and white vision inspection system2312, in turn, receive trigger signals from the PLC, and output aninspection result to the PLC tracking system. An Ethernet switch 2306interconnects the control panel 2302, the computer 2304, the colorvision inspection system 2310, and the black and white vision inspectionsystem 2312. The connection between the strobe controller 2314 and thecontrol panel 2302 may be a USB connection in certain examples, and theservo drives 2308 a and 2308 b may be connected to the servo controllerof the computer 2304 with fiber optic cabling. Of course, other types ofwired or wireless connections as between the various components andsub-components may be provided in different embodiments of theinvention.

Recipes may be stored, e.g., in a non-transitory computer readablestorage medium. The recipe information may include, for example, thenumber of carrier bars, the number of pockets per carrier bar,distance(s) between carrier bars and/or pockets, tolerance levels fordefects, reference images, whether one or both types of cameras are tobe used, reporting requirements, etc. Multiple recipes may be pre-storedor stored by the user/operator (e.g., for later use), therebyfacilitating quick changeover. Each recipe may be uniquely identified insome cases.

In certain forms of the invention, the vision system may be a part of adistributed processing environment. The vision system may, for example,include one or more inspection stations that operate independent of eachother, as alluded to above. In situations where a one-sided grayscaleinspection is desired, a single inspection station may be used. Insituations where two-sided inspection, or color and grayscale inspectionare desired, two or more inspection stations may be used. Smart camerasare mounted adjacent to one another other in a row, above the carrierbars, and/or below the eject drum in the case of two-sided inspection.Each smart camera (sometimes referred to as a vision sensor) isresponsible for inspecting an area of the carrier bar, and each cameracontains a dedicated processor to perform its inspection task. Thisarrangement is advantageous for several reasons. For example, thecamera's captured image data does not have to be sent over a cable to acentral processing computer. This transfer of data, especially whenthere are multiple inspection stations, can cause a slower operatingspeed, e.g., to account for the time required to transfer the largeamount of raw image data. With the smart cameras, the processing isperformed within the camera, thereby changing the amount and type ofdata to be transferred. In certain instances, raw or processed imagedata need not be transmitted from the cameras, at all. Another advantageis that additional cameras can be added to the system without causing anincrease in the overall processing time. Each smart camera contains itsown dedicated processor, so cameras (and therefore processors) can beadded to increase the speed and throughput of the system. By contrast,in some conventional arrangements, the addition of additional camerasactually slows processing. Still another advantage is that the camerashave much longer longevity without becoming obsolete as compared to anindustrial computer. The fast obsolescence rate for computers can causeFDA validation problems if the exact same model is not available as adirect replacement for a failed computer, as some rules may specify thatthe replacement of an individual component must be accompanied by thecertification of the replacement component and/or re-certification ofthe apparatus. Thus, an advantage of certain forms of the invention isthat the self-contained vision system may be easily validated based onfunctionality alone. In some cases, the small package approach ofproviding a camera and image processing hardware and software enables ashort validation procedure to be implemented, thereby making the upgradeto a new version of the vision system simple fairly straightforward fromimplementation and/or certification perspectives.

The following example components may be used in connection with certainembodiments. Of course, other components may be used in connection withdifferent embodiments of this invention.

-   -   Touch-Screen Computer for control panel        -   Specifications: Allen Bradley 6181F Integrated Display            Computer, 17″ Touch-Screen Monitor, Intel Core Duo 1.2 GHz            Processor, 1 GB Dual-Channel DDR2 RAM, 24 VDC, Solid-State            CompactFlash Drive        -   Operating System: Microsoft Windows XP Professional SP2        -   Software: Machine interface program and supporting DLL files            developed by Ackley Machine Corporation using Microsoft            Visual Basic 2010 version 10.0.30319.1        -   Cognex In-Sight Explorer Camera Interface Program version            4.04.01        -   Advanced Illumination Pulsar 320 Strobe LED Lighting            Controller Interface Program version 1.0078125.2    -   PLC Motion Controller        -   Specifications: Allen Bradley 1768-L43 CompactLogix PLC, 2            MB Ram        -   Firmware Revision: 17.3.59        -   The PLC machine control program was created using Rockwell            Automation RSLogix 5000 PLC Programming Software    -   Control Panel Computer to PLC Communication        -   The control panel computer communicates with the PLC via an            Ethernet connection        -   The control panel computer to PLC communication program and            related support files were created using Cimquest INGEAR.NET            Developer Edition    -   Color Inspection Cameras        -   Specifications: Cognex In-Sight 5400 Color Progressive Scan,            640×480 Resolution, 24 VDC        -   Camera Firmware Version: 4.04.01        -   Cameras are programmed using Cognex In-Sight Explorer            software version 4.04.01        -   Cameras are equipped with a full library of Cognex vision            tools including PatMax    -   Grayscale Inspection Cameras        -   Specifications: Cognex In-Sight 5603 Progressive Scan, 1 GHz            Processor, 1600×1200 Resolution, 24 VDC        -   Camera Firmware Version: 4.04.01        -   Cameras are programmed using Cognex In-Sight Explorer            software version 4.04.01        -   Cameras are equipped with a full library of Cognex vision            tools including PatMax    -   Camera to PLC Communication        -   The cameras communicate with the PLC via Ethernet connection        -   The camera to PLC communication program was developed using            Cognex Connect AOP (Add-On Profile) to provide            pre-configured device command outputs    -   Camera to HMI Computer Communication: The cameras communicate        with the HMI computer using standard Ethernet TCP/IP protocol

FIG. 24 is a side view of the conveyer apparatus of FIG. 1, with aportion of the apparatus shown in cross-section, modified to includeadditional cameras in accordance with an example embodiment, and FIG. 25is a top view of the conveyer apparatus of FIG. 24. FIGS. 24 and 25 aresimilar to FIGS. 2 and 3, except that multiple color cameras (first andsecond color cameras 2402 a and 2402 b) are provided upstream of themultiple black and white or grayscale cameras and substantially in linewith one another. The vertical positioning may be the same or differentas between the different types of cameras. The color cameras may becentered or substantially centered horizontally between the width of theblack and white or grayscale cameras when there are more black and whiteor grayscale cameras than color cameras, and vice versa. Although thenumber of color cameras is one-half the number of black and white orgrayscale cameras, different numbers and/or ratios may be provided indifferent embodiments. In addition, the centering or substantialcentering need not always be true, as fewer cameras may be located atthe extremities and possibly angled inwardly, offset to accommodatedifferent structures or carrier bars, etc. Furthermore, the numbers ofdifferent types of cameras may be selected in part on the number ofpockets in a row bar. Generally, the fewer pockets, the fewer camerasthat may be provided. And generally, the higher the desired throughput,the more cameras that may be provided. In certain examples, one blackand white or grayscale camera may service six pockets of a carrier bar,whereas one color camera may service 12 pockets of a carrier bar.

FIG. 26 is an example operation screen that may be displayed to auser/operator in accordance with an example embodiment. The left side ofthe example screen includes inspection result statistics including, forexample, the total number of accepted and reject products, as well asthe overall yield. A more detailed breakdown of results by camera(including yield per camera and dropped rows per camera) also isprovided, and similar breakdowns may be provided as between the colorversus black and white or grayscale cameras. Camera performance also maybe shown according to calculated or raw metrics. For instance, cameratime performance may be measured as inspection time divided by bartime*100%. The calculation may be performed since the last time thecounters were reset. Empty pockets may or may not be included in thiscalculation. The overall status of the apparatus may be shown, e.g., inconnection with a green/yellow/red stoplight type display (for running,idle, or stopped progress) and/or these may be functional buttons tocause the machine to run, idle, or stop, and basic details regarding theproduct (e.g., name), batch number or identifier, total run time, systemspeed (e.g., in terms of bars/minute, etc.), and ejection status (e.g.,in terms of dropped rows) may be provided. Other information pertainingto whether the vacuum pump is on, whether the viscosity pump is enabled,whether the doctor blade is on (either in automatic or manual mode),what the bar fill rate percentage is, etc., also may be provided.

FIG. 27 is an example operation screen that includes overall equipmenteffectiveness (OEE) performance monitoring in accordance with an exampleembodiment. FIG. 27 is similar to FIG. 26. However, the overallefficiency of the printing system is also tracked through the OEEmonitoring system and is displayed in FIG. 27. Real-time information isdisplayed relating to the availability, performance and quality ratingsfor each batch and/or shift.

FIG. 28 is an example design roll data matrix screen in accordance withan example embodiment. The design roll data matrix screen displays a boxfor each etched logo contained on the design roll. The grid is shown asplotting logo position against pocket position. Inside each box, anumber is displayed that tracks the total quantity of rejected productfor logo defects from the corresponding etch on the design roll. Thisinformation can be used to diagnose the cause of detected defects andsuggest possible solutions, thereby potentially reducing the number ofdefects and improve the process. For example, if a design roll etch isclogged with dried ink, there will be a greater number of defectsoriginating from that etch on the design roll than the other non-cloggedetches. This can be easily seen by looking at the matrix for abnormallylarge numbers in comparison with the other locations within the matrix.Another example is when the rubber offset roll has developed a flatsurface, which occurs if the design roll is left on impression with therubber offset roll for an extended period of time while the machine isnot in operation. This type of defect can be easily seen in the matrixby looking for one or two rows of abnormally large defect numbers acrossthe design roll (for example, two rows, such as rows 6 and 7—althoughnot necessarily borne out in the FIG. 28 example screen). The grid maybe generated, as the cameras are able to detect problems, while alsokeeping track of which pockets and which carrier bars the problems arein, which printers are implicated by the detected defects, as well as atime of the problem. Count data may be maintained by the camerasthemselves and/or fed back to the PLC in certain implementations as theyoccur or in batch. It will be appreciated that in certainimplementations, the data used to create the matrix may the same orsimilar data as that involved in the vacuum pickup and selectivedepositing in the accept or reject areas.

In certain example embodiments, the selection of a particular part ofthe matrix may cause the relevant portions of the apparatus to become atleast partially exposed. For instance, the design and/or rubber rollsmay be rotated and/or raised so that a user/operator may visuallyinspect the areas that possibly have contributed to detected errors. Insome cases, it may be possible to notice the wearing away of a portionof the design, a flattened or raised area of the rubber transfer roller,material stuck or lodged in various places, etc. A user/operatortherefore may have an easier time diagnosing potential issues.

FIG. 29 is a screen that provides a single point of control for printingand vision system access in accordance with an example embodiment. Thesystem's control panel or user interface may be hosted on a computerthat includes a front-end program that communicates with controlcomponents on the machine. In certain implementations, all controlcomponents may be accessed and/or controlled via this program including,for example, all inspection cameras and lighting control. Similarly, incertain implementations, all setup parameters, system statusinformation, and operational controls for both the printer and theautomatic vision inspection may be contained within a single program(e.g., operating on a Windows XP based computer). On the vision screen,the real-time display window for each camera may be displayed across thescreen to simulate the actual layout of the carrier bar. Each camerawindow may be zoomed-in to display a larger picture, and each camera maybe controlled either individually through the camera tabs (e.g., manualtrigger, live mode, etc.), or as a single inspection station through theglobal vision settings tab (e.g., overall inspection results, acceptancethreshold settings, etc.). Pocket-by-pocket inspection results also maybe provided, as may the overall accept/reject/yield data. The FIG. 29example also includes the IP addresses of the cameras and theirrespective statuses (connected/disconnected).

FIG. 30 is an example screen for vision system setup and logo trainingin accordance with an example embodiment. The user interface may includecontrols to facilitate training of the logos and inspection regions foreach camera. For instance, controls may be provided that allow thesystem to be trained specifically for print defect inspection, brokentablet inspection, coating defect inspection, etc. As shown in the FIG.30 example screen, an enlarged view of a carrier bar is provided, withproducts located in its pockets. The user may initiate an automatictablet presence detection and/or manually set or refine the detection soas to aid in training. For instance, a user may, for each pocket,specify the X and Y positions and/or distances of the logo, the angle atwhich the logo is offset relative to the cameras, etc. This training maybe performed for each camera and/or globally. A digital image of thelogo also may scanned for training purposes.

Search regions may be defined relative to the pockets and/or carrierbars. Cameras also may be physically positioned or repositioned to aidwith recognition. In certain cases, a user/operator may train the systemby placing a quality printed table in one of the pockets to be viewed bya first camera. A box may appear, enabling the user/operator to definethe boundaries of the logo. This procedure may be repeated for eachcamera. Row and column graphic offsets may also be specified in certainexample implementations.

FIGS. 31 and 32 are example user maintenance screens in accordance withan example embodiment. The user interface may support multiple userlogins. The users may have the same or different privileges. Thus, usersmay be added, deleted or modified. The password requirements and levelof access for each user can be customized to meet any customer'sstandard procedures. For example, some users may have read-only accessto the data, whereas other users may have the authority to changeoperating parameters, alter tolerance thresholds, initiate productchangeovers, etc. Individual buttons or entire screens can belocked-down to prevent unauthorized users from accessing criticalmachine settings and/or functions. Predefined categories (e.g.,administrator, engineer, mechanic, operator, etc.) may be provided,sometimes with default permissions, to suit the different operations.FIG. 32 in particular shows various screens and controls and enablespermissions for the defined groups of users to be correspondingly set.Of course, it will be appreciated that other control mechanisms forthese and/or other screens and/or features may be used in differentembodiments.

FIG. 33 is an example automatic vision system calibration verificationscreen in accordance with an example embodiment. A “calibration check”wizard may be provided. The wizard may in certain scenarios includeon-screen instructions for the purpose of verifying that the cameras arecalibrated correctly at the start of a batch. Specially designed carrierbars for both the color and grayscale cameras are conveyed underneaththe cameras. The cameras capture high resolution images of thecalibration bars, and compare the results with pre-set thresholds todetermine if the cameras are properly calibrated. A bar check functionmay be provided to inspect each carrier bar installed along theconveyor, with the bar check function inspecting each bar to determineif it is the correct bar for the selected recipe, whether products arestuck in the carrier bar pockets, whether the carrier bars are installedin the correct orientation, etc. The wizard itself may walk the userthrough several ordered steps to ensure that the above and/or otheraspects of the system are working properly.

Although certain example embodiments have been described herein asrelating to tablets, it will be appreciated that the example techniquesdescribed herein may be applied to various other kinds of products suchas, for example, pharmaceutical products, confectionery products, etc.,which may be in tablet, capsule, soft-gel, and/or other forms. Theexample techniques described herein may accommodate various sizes andshapes of products including, for example, circular, ovular, oblong,square, rectangular, and/or other shapes. Furthermore, although certainexample embodiments have been described as printing, the techniquesdescribed herein may be applied to other forms of processing. Forinstance, engraved or embossed patterns produced in other ways also maybenefit from, for example, the example vision, tracking, and/or othertechniques described herein. Dyed products also may benefit from theexample techniques described herein. Errors or imperfections may bedetected in other processing contexts in different forms of theinvention. For instance, the techniques described herein may be applieddownstream of any processing that might result in damage to a productsuch as, for example, chipping, breaking, flaking, smearing, smudging,etc., where logos, images, or other text is/are or is/are not involved.

While the invention has been described in connection with what arepresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the invention. Also, the various embodiments described abovemay be implemented in conjunction with other embodiments, e.g., aspectsof one embodiment may be combined with aspects of another embodiment torealize yet other embodiments. Further, each independent feature orcomponent of any given assembly may constitute an additional embodiment.

What is claimed is:
 1. A system configured for use with a conveyerapparatus including a plurality of carrier bars, each carrier bar beingstructured to convey a plurality of pellet-shaped articles along apredetermined path, the inspection system comprising: at least onecamera configured to sense the plurality of pellet-shaped articles beingconveyed along the predetermined path; a lighting assembly configured toilluminate the pellet-shaped articles as they are being sensed by the atleast one camera; a removal unit, downstream of the at least one camera,structured to remove the plurality of pellet-shaped articles from theplurality of carrier bars; and at least one processor in communicationwith the at least one camera and the removal unit, the at least oneprocessor being configured to at least: determine whether at least firstand second predetermined characteristics are present for the pluralityof pellet-shaped articles as the plurality of pellet-shaped articles arebeing conveyed along the predetermined path, the first predeterminedcharacteristic being indicative of a coating for a given pellet-shapedarticle and the second predetermined characteristic being indicative ofa hole therein, and provide a control signal to the removal unit independence on determinations made in connection with the at least firstand second predetermined characteristics, wherein the removal unit isconfigured to remove the articles by suction, responsive to the controlsignal received from the at least one processor.
 2. The system of claim1, wherein the at least one camera is configured to sense the pluralityof pellet-shaped articles being conveyed along the predetermined pathwhile the they are lying in pockets of the carrier bars.
 3. The systemof claim 1, wherein the removal unit includes a rotatable ejection drumhaving a plurality of vacuum nozzles, the vacuum nozzles beingstructured to remove the articles by suction depending on the at leastfirst and predetermined characteristics, responsive to the controlsignal received from the at least one processor.
 4. The system accordingto claim 3, wherein the vacuum nozzles are structured to remove all ofthe articles by suction and selectively release suction applied to allof the articles to release the articles into one of an accept bin and areject bin depending on the at least first and predeterminedcharacteristics, responsive to the control signal received from thecontroller.
 5. The system according to claim 3, wherein the removal unitis configured to selectively remove articles by suction which areacceptable and passively allow rejected ones of the articles to beremoved.
 6. The system according to claim 1, wherein the at least onecamera includes first and second cameras, the first camera beingconfigured to provide data related to the first predeterminedcharacteristic and the second camera being configured to provide datarelated to the second predetermined characteristic.
 7. The systemaccording to claim 6, wherein the at least one camera includes a firststage of cameras and a second stage of cameras, the first stage ofcameras being configured to provide data related to the firstpredetermined characteristic and the second stage of cameras beingconfigured to provide data related to the second predeterminedcharacteristic.
 8. The system according to claim 1, wherein the lightingassembly includes one or more LED lights.
 9. The system according toclaim 8, wherein the lighting assembly further comprises a domestructure including a reflective interior surface adapted to reflectlight from the LED lights onto the articles being sensed.
 10. The systemaccording to claim 1, wherein: the at least one camera includes aplurality of cameras; the at least one processor comprises a pluralityof processors; each of the cameras has distributed thereto one of theplurality of processors, the processors being usable in to performdistributed defect and/or error detection in connection with theplurality of articles.
 11. A method of making a genuine batch ofpellet-shaped articles, each of the pellet-shaped articles in thegenuine batch being free from defects of a predefined magnitude, themethod comprising: separating acceptable pellet-shaped articles to beincluded in the genuine batch, from unacceptable pellet-shaped articlesto be excluded from the genuine batch, via a system according to any oneof claim 1; and packaging together the separated acceptablepellet-shaped articles in making the genuine batch.
 12. A method ofoperating an inspection system being used with a conveyer apparatusincluding a plurality of carrier bars, each carrier bar being structuredto convey a plurality of pellet-shaped articles along a predeterminedpath, the method comprising: sensing, via at least one camera, theplurality of pellet-shaped articles being conveyed along thepredetermined path; illuminating the pellet-shaped articles as they arebeing sensed by the at least one camera; determining whether at leastfirst and second predetermined characteristics are present for theplurality of pellet-shaped articles as the plurality of pellet-shapedarticles are being conveyed along the predetermined path, the firstpredetermined characteristic being indicative of a coating for a givenpellet-shaped article and the second predetermined characteristic beingindicative of a hole therein; and providing a control signal to aremoval unit structured to remove the plurality of pellet-shapedarticles from the plurality of carrier bars in dependence ondeterminations made in connection with the at least first and secondpredetermined characteristics, wherein the removal unit is configured toremove the articles by suction, responsive to the control signalreceived from the at least one processor.
 13. The method according toclaim 12, wherein the removal unit includes a rotatable ejection drumhaving a plurality of vacuum nozzles, the vacuum nozzles beingstructured to remove the articles by suction depending on the at leastfirst and predetermined characteristics, responsive to the controlsignal received from the at least one processor.
 14. The methodaccording to claim 13, wherein the vacuum nozzles are structured toremove all of the articles by suction and selectively release suctionapplied to all of the articles to release the articles into one of anaccept bin and a reject bin depending on the at least first andpredetermined characteristics, responsive to the control signal receivedfrom the controller.
 15. The method according to claim 13, wherein theremoval unit is configured to selectively remove articles by suctionwhich are acceptable and passively allow rejected ones of the articlesto be removed.
 16. The method according to claim 12, wherein the atleast one camera includes first and second cameras, the first camerabeing configured to provide data related to the first predeterminedcharacteristic and the second camera being configured to provide datarelated to the second predetermined characteristic.
 17. The methodaccording to claim 16, wherein the at least one camera includes a firststage of cameras and a second stage of cameras, the first stage ofcameras being configured to provide data related to the firstpredetermined characteristic and the second stage of cameras beingconfigured to provide data related to the second predeterminedcharacteristic.
 18. The method according to claim 12, wherein: the atleast one camera includes a plurality of cameras; the at least oneprocessor comprises a plurality of processors; each of the cameras hasdistributed thereto one of the plurality of processors, the processorsbeing usable in to perform distributed defect and/or error detection inconnection with the plurality of articles.
 19. The method according toclaim 12, further comprising generating for output to a display device afirst display area including real-time video output, including at leasta portion of the conveyor, from the at least one camera.
 20. The methodaccording to claim 19, further comprising generating for output to thedisplay device a second display area including calculated inspectionstatistics.